Miller Electric SGA 100, SGA 100C Owner's Manual

Owner’s Manual
SGA 100 And SGA 100C

1. Safety Symbol Definitions

June 2000 FORM: OM-190 753F

Use above FORM number when ordering extra manuals.

Warning! Watch Out! There are possible hazards as
shown in the adjoining symbols.

Beware of electric shock from wiring. Turn Off welding
power source and disconnect power before installing this
kit. Reinstall all panels and covers.

Wear safety glasses with side shields.

NOTE

The SGA 100 and SGA 100C are not required for use with the Millermatic 185 and
IronMan 210 models, and IronMan 250 models effective with serial no. LA135884

Have only trained and qualified persons install, operate,
or service this unit. Call your distributor if you do not un­derstand the directions. For WELDING SAFETY and
EMF information, read welding power source Owner’s
Manual.

Hot parts can cause burns. Welding makes parts very hot

− let them cool before touching.

and following).

2. Weld Control Specifications

Specification

Input Power Single-Phase 115 Volts AC, .5 Amperes, 60 Hertz

Control Circuit Voltage Provided To Spool Gun 36 Volts DC

Welding Power Source Type Constant Voltage (CV) DC, With or Without Contactor

Connections Gun Trigger Controls, Gas And Weld Cables

Welding Process DC Gas Metal Arc Welding (GMAW)

Input Power Cord With Plug 10 ft (3 m)

Overall Dimensions SGA 100: 13 in (330 mm) L x 8 in (203 mm) W x 5 in (127 mm) H

Weight SGA 100: 10 lb (4.5 kg); SGA 100 C: 13 lb (5.9 kg)

SGA 100C: 13 in (330 mm) L x 8 in (203 mm) W x 9 in (229 mm) H

3. Duty Cycle

Maximum rating for the SGA 100
and SGA 100C is 150 amperes at a
60% duty cycle.

Duty Cycle is percentage of 10 mi n ­utes that unit can weld at rated load

6 Minutes Welding 4 Minutes Resting

without overheating.

NOTE: If you are connecting this spoolgun adapter to a unit with an output contactor, proceed to Section 4. If you are
connecting this spoolgun adapter to a unit without an output contactor, proceed to Section 5.

 2000 MILLER Electric Mfg. Co.

4. Installing SGA 100 Spoolmate Adapter (Kit 043 856)

A. Making Connections To Units With An Output Contactor (Millermatic 185 And IronMan 210 Models, And

IronMan 250 Models Effective With Serial No. LA135884 And Following Do Not Require This Accessory)

.Drawing shows typical welding

power source installation.

1

2

9

3

8

6

7

7

4

8

10

5

11

12

Tools Needed:

3/4 in

Y Turn Off and disconnect input

power.

1 Spoolmate 185 Or Spoolmate 250
2 SGA 100 Control Box
3 Welding Power Source With 1/2 in

(13 mm) Weld Cable Stud
4 1/2 in (13 mm) Weld Cable Stud
5 Front Panel
6 Front Panel Opening
7 Spoolgun Weld Cable
Route Spoolgun weld cable through front

panel opening and connect to 1/2 in (13

OM-190 753 Page 2

mm) weld cable stud. NOTE: if unit does
not have a 1/2 in (13 mm) weld cable stud,
proceed to Section 3B

8 Interconnecting Cord
Connect interconnecting cord as shown.

NOTE: a second interconnecting cord with
female friction terminals on each end (not
shown) is p r o v i d e d w ith this kit. If your unit
requires this type of interconnecting cord,
connect female friction terminals to match­ing male friction terminals on front panels of
welding power source and SGA 100 con­trol box. Polarity is not important.

9 Spoolgun Gas Hose
Slide spoolgun gas hose onto barbed fitting

on SGA 100 control box where shown.
10 Spoolgun Trigger Control Plug
Connect spoolgun trigger control plug to

matching receptacle on SGA 100 control
box where shown.

11 Gas Hose
Slide gas hose onto fitting on back of SGA

100 control box.
12 115 VAC Plug
Connect plug as shown.

Ref. ST-802 181

B. Connecting Spoolmate Spoolgun Weld Cable To Units Without A 1/2 in Weld Cable Stud

Tools Needed:

5/16 in

.Drawing shows typical welding

power source installation.

2

3

1

1 Wire Drive Assembly
2 Gun Securing Bolt
3 Gun Securing Nut
Remove gun securing nut.
4 Terminal
Slide terminal onto gun securing bolt

and secure with gun securing nut.
5 Spoolgun Weld Cable Ring

Terminal

Cut off ring terminal and strip insula­tion back 1/2 in (13 mm).

Slide spoolgun weld cable into termi­nal 1/2 in (13 mm). Tighten set­screw.

Go back to Section 3A, Item 8, to
complete the installation.

4

1/2 in

5

Ref. ST-802 181

OM-190 753 Page 3